Abstract: As a key process for the manufacture of complex aero-engine components, selective laser melting (SLM) offers significant advantages in achieving functional integration and shortening production cycles. However, challenges still remain in support structure design and defect control. A certain type of aero-engines fuel nozzle housing was adopted as the research object. The SLM forming principle and cracking cases induced by unreasonable typical supports were analyzed.Combined with fluorescence inspection fault diagnosis and cleanliness monitoring technology, a whole-process quality control scheme from support structure optimization to post-processing was proposed. The results show that using simulation analysis to identify stress concentration regions and optimize the support structure, together with a reasonable non-destructive testing sequence, can significantly improve the forming quality and service reliability of nozzle components.